Dispenser System

ABSTRACT

A moulded fibrous end plug and dispenser system comprising the same, the end plug for use in mounting a roll of sheet material to a dispenser and having a roll facing side comprising formations configured to be insertable into an opening in an end of a roll of sheet material and for securing the end plug to the roll of sheet material, the end plug further comprising an opposite dispenser facing side comprising formations configured to cooperate with formations of a roll holder portion of a dispenser in use for mounting the end plug to the dispenser.

This application claims priority from French Patent Application No. 2008404, which may be referred to by attorney docket number 65080048FR01, and UK Patent Application No. 2017786.1, which may be referred to by attorney docket number 65080048GB03.

The present invention relates to an end plug for use in mounting a roll of sheet material to a dispenser, and to methods of manufacturing and using such an end plug. The invention also extends to a dispenser system including such an end plug and to a system comprising a roll of sheet material having such an end plug inserted in an opening in an end of the roll.

End plugs may be used to mount a roll of sheet material to a dispenser. An end plug may be associated with one or both ends of the roll, and is used to connect the respective end of the roll to the dispenser. Typically one side of the end plug (the roll facing side) is configured to be inserted into an opening in a respective end of the roll of sheet material, while the other side of the end plug (the dispenser facing side) is configured to be mounted to a roll holder portion of the dispenser. End plugs may be used with a range of dispenser types, and are may be used with wall mounted dispensers (whether manually operated or of an electronic “hands-free” type).

End plugs may facilitate obtaining secure mounting between the roll and the dispenser. The dispenser facing side of an end plug may be configured such that the end plug only fits a particular type of dispenser. For example, the dispenser facing side of the end plug and a roll holder portion of the dispenser may comprise complementary formations, e.g. intended to mate with one another. In this way, an end plug may be used to ensure that only a type of roll of sheet material with which the dispenser is intended to be used may be inserted into the dispenser, helping to provide improved operation of the dispenser system. For example, a dispenser may be designed to operate most effectively with certain types of roll, e.g. including material of a particular basis weight, and/or of a given size. If a different roll type is used with the dispenser, it may not operate effectively e.g. the material may tend to jam, or may give a perception of lower quality. In the case of an electronic dispenser, use of an inappropriate roll size may cause the motor to be overloaded or to operate at a sub-optimal power consumption.

A roll of sheet material may be supplied with an end plug inserted in one or both ends thereof. This may provide a refill for a dispenser.

A dispenser system for rolled sheet material products including end plugs is described in US 2012/0138723A1 (Lewis at al), published on 7 Jun. 2012.

The Applicant has realised, however, that there is scope to provide an improved end plug for use in mounting a roll of sheet material to a dispenser.

In accordance with a first aspect of the present invention there is provided;

-   -   a moulded fibrous end plug for use in mounting a roll of sheet         material to a dispenser, wherein the end plug has a roll facing         side comprising formations configured to be insertable into an         opening in an end of a roll of sheet material, the formations of         the roll facing side including formations for securing the end         plug to the roll of sheet material in use; and an opposite         dispenser facing side comprising formations configured to         cooperate with formations of a roll holder portion of a         dispenser in use for mounting the end plug to the dispenser.

The present invention therefore provides an end plug formed by moulding a fibrous material. In contrast to previous end plugs, such as those described in the above-mentioned US 2012/0138723A1 (Lewis at al), which are made from a plastics material, the end plug of the present invention is provided by a moulded fibrous structure. This provides a more sustainable end plug which is advantageously biodegradable.

The end plug of the present invention may also provide advantages in terms of ease of recycling. An end plug is typically removed from the dispenser along with a roll core (where provided) for disposal once a roll of sheet material has depleted. The end plug may remain inserted in the end of the core. The roll core is typically made of cardboard, paperboard or similar fiber based material. If the end plug is made of a plastics material, it may need to be removed from the core to ensure that the core may be recycled without risk of contaminating the core recycling waste stream. The plastic end plug may or may not itself be recyclable depending upon plastic recycling availability in a given area. Even if recycling is possible, in many cases a plastic end plug would need to be separated from the core to ensure that both the core and plug may be effectively recycled without contaminating a particular recycling waste stream. For example, recycling processes often require the separation of plastic and paper materials into separate streams, whether on disposal by a user or subsequently during the recycling process. Providing an end plug that cannot easily be recycled along with a roll core may therefore result in a user either failing to recycle either part, and instead putting the core along with the end plug into a non-recyclable waste stream, or placing both parts as a unit into a recycling waste stream that is inappropriate for one or other of the materials.

In contrast, the end plug of the present invention may be disposed of together with a roll core (where provided) into a single recycling waste stream, without risk of contamination. The end plug and core may be recycled as a unit using widely available recycling services for non-plastic materials. This provides greater convenience for the user, and reduced environmental impact, increasing the likelihood of successful recycling. Even where the end plug is used without a core, the ability to readily recycle the end plug e.g. with paper waste, provides improved sustainability in contrast to plastic end plugs.

In some embodiments at least, the end plug is biodegradable, and may be compostable, providing further advantages. This may facilitate disposal whether by the consumer, or following a commercial recycling process.

The end plug of the present invention is a moulded end plug for use in mounting a roll of sheet material to a dispenser. The end plug connects an end of the roll to a roll holder portion of the dispenser in use. The end plug may extend between the end of the roll and the roll holder portion of the dispenser to connect the roll and the roll holder portion of the dispenser. A portion of the end plug may be sandwiched between the end of the roll and a portion of the roll holder portion of the dispenser.

The end plug has opposed roll facing and dispenser facing sides comprising formations configured respectively to be insertable into an opening in an end of a roll of sheet material and including formations for securing the end plug to a roll of sheet material, and for mounting the end plug to a holder portion of a dispenser in use.

The end plug defines an axial direction and a radial direction. The end plug has a central axis. The central axis of the end plug may be aligned with a central axis of a roll (and where applicable, of a core of the roll) when mounted thereto in use. A circumferential direction is defined as a circumferential direction with respect to the axis of the end plug.

A reference to upper, higher, top or increasing height etc, herein in respect of the roll facing side of the end plug refers to the direction/positions further from the dispenser facing side of the end plug, while, conversely, references to lower, bottom, decreasing height etc. refer to the direction/positions closer to the dispenser facing side of the end plug.

The end plug is a moulded fibrous end plug. The formations associated with the roll facing and dispenser facing sides thereof are moulded formations. The end plug is an integrally moulded end plug. The moulded formations are integrally moulded formations.

The roll facing side of the end plug comprises formations configured to be insertable into an opening in an end of a roll of sheet material. These formations insertable into the opening in the end of the roll of sheet material may be referred to as “formations of the roll facing side”. These formations include formations for securing the end plug to the roll of sheet material. The formations of the roll facing side for securing the end plug to the roll of sheet material may comprise formations configured to provide an interference fit securing the end plug to the roll. The interference fit is between the formations and the outer periphery of the opening in the end of the roll. This may be defined by a core of the roll in embodiments using a cored roll, or, for a coreless roll, may be defined by a portion of the sheet material of the roll in which the opening is defined. The interference fit may be such that the end plug cannot easily be removed from the roll. This may mean that the end plug is typically disposed along with any residual part of a depleted roll e.g. a core, where used. The present invention facilitates recycling of an end plug along with such a residual roll part.

The dispenser facing side of the end plug comprises formations configured to cooperate with formations of a roll holder portion of a dispenser (i.e. the roll facing side thereof) for mounting the end plug to the dispenser. The formations of the dispenser facing side enable the end plug to be mounted on to a roll holder portion of a dispenser with which the end plug is intended to be used without constraint.

The formations of the dispenser facing side of the end plug and the formations of the roll holder portion which cooperate with one another may comprise at least one respective set of one or more formations of the dispenser facing side of the end plug and one or more formations of the roll holder portion that are complimentary to one another. The respective sets of one or more formations may each define one of a pair of complimentary parts.

At least some of the respective cooperating formations of the end plug and roll holder portion may be arranged to engage one another to mount the end plug to the dispenser. For example, a mating engagement may be provided. The end plug may provide a female part and the roll holder portion a male part of the mating connection. However, it will be appreciated that not all of the cooperating formations of the dispenser facing side of the end plug and formations of the roll holder portion need necessarily engage one another for mounting the end plug to the dispenser.

At least some of the cooperating formations of the dispenser facing side of the end plug and roll holder portion may cooperate with one another in that they do not interfere with the interaction between others of the cooperating formations of the dispenser facing side of the end plug and roll holder portion required to mount the end plug to the roll holder portion of a dispenser with which the end plug is intended to be used e.g. by enabling complimentary sets of one or more formations of the dispenser facing side of the end plug and the roll holder portion to properly engage one another to provide a secure mounting. It will be appreciated that the formations may, in this way, be used to ensure that the end plug may only be used with a roll holder portion with which they are intended to be used, preventing the end plug from being properly fitted onto other dispensers.

Various features of the formations of the dispenser facing side of the end plug will now be described. These may be described by reference to features of the dispenser or roll holder portion thereof, with which they interact. The invention extends to the dispenser facing side having formations configured to interact with the dispenser/roll holding portion thereof in the manner described, and also extends to a dispenser system including the end plug and a dispenser.

The formations of the dispenser facing side may be configured to enable the end plug to be rotatably mounted to the roll holder portion. This will allow the end plug to rotate with the roll of sheet material relative to the roll holder portion during dispensing of sheet material.

However, alternatively the formations of the dispenser facing side may be configured to enable the end plug to be fixedly mounted to the roll holder portion i.e. such that relative rotation between the roll holder portion of the dispenser and the end plug is prevented. In such embodiments, the roll holder portion may be adapted to be rotatable relative to a cooperating portion e.g. an adjacent portion of the dispenser to permit rotation of the roll relative to at least a portion of the dispenser once mounted for the dispensing of sheet material. The cooperating portion of the dispenser may, for example, be an arm of the dispenser. The roll holder portion may be mounted to the arm of the dispenser via a mounting portion, such as a hub, that is rotatable relative to the arm. The mounting portion may be disposed on the arm e.g. at the distal end of the arm. In some embodiments the formations of the dispenser facing side may be configured to cooperate with the formations of the roll holder portion to enable the end plug to be mounted to the roll holder portion in a fixed rotational orientation relative to the roll holder portion. For example, the formations of the dispenser facing side may comprise formations configured to cooperate with formations of the roll holder portion to provide a keyed connection between the end plug and the roll holder portion. This may be achieved in any suitable manner.

The present invention extends to a dispenser system comprising a moulded fibrous end plug in accordance with the invention in any of its aspects or embodiments and a dispenser comprising a roll holder portion comprising formations configured to cooperate with the formations of the dispenser facing side of the end plug for mounting the end plug to the dispenser in use. The formations of the roll holder portion are formations of a roll facing side of the roll holder portion. The roll facing side faces an end of the roll.

It will be appreciated that any of the further aspects of the invention may include any or all of the features of the invention described in relation to any other aspects and embodiments of the invention to the extent they are not mutually inconsistent therewith. In particular, it will be appreciated that the invention in the second and further aspects may comprise any or all of the features described in respect of the method of the first aspect of the invention, and vice versa.

The present invention further extends to a dispenser system comprising;

-   -   a dispenser for a roll of sheet material, the dispenser         comprising a roll holder portion;     -   a roll of sheet material having an opening in an end thereof;     -   and a moulded fibrous end plug in accordance with the invention         in any of its aspects or embodiments secured to the end of the         roll of sheet material;     -   wherein the formations of the roll facing side of the end plug         configured to be insertable into an opening in an end of a roll         of sheet material are inserted into the opening in the end of         the roll of sheet material;     -   and wherein the formations associated with the dispenser facing         side of the end plug cooperate with formations of the roll         holder position of the dispenser to mount the end plug to the         dispenser.

The end plug thus mounts the end of the roll to the roll holder portion of the dispenser.

Formations of the roll facing side of the end plug are axially inserted into the opening at the respective end of the roll.

The formations of the roll facing side of the end plug that are insertable into an opening in an end of a roll comprise formations which secure the end plug to the roll of sheet material. Thus, the formations associated with the roll facing side of the end plug which are insertable into an opening in an end of a roll are inserted into the opening in the end of the roll of sheet material with the formations for securing the end plug to the end of the roll of sheet material securing the end plug to the end of the roll of sheet material. References herein to the formations associated with the roll facing side being inserted into the opening in the end of the roll of sheet material to secure the end plug to the end of the roll of sheet material should be understood in this way.

It will be appreciated that the roll facing side may include formations insertable into the opening which do not necessarily directly contribute to securing the end plug to the roll, but may support the securement of the end plug to the roll e.g. by enhancing the structural integrity of the end plug.

These further aspects and embodiments of the invention may incorporate any of the features described in relation to the earlier aspects and embodiments of the invention to the extent they are not mutually exclusive. The end plug, and the roll facing and dispenser facing sides thereof, may include any of the features described earlier. Likewise, the roll holder portion and roll may include any of the features previously described, and may cooperate with the end plug in any of the manners described.

In accordance with these further aspects and embodiments of the invention the roll of sheet material is rotatably mounted to the dispenser to enable rotation of the roll relative to at least a portion of the dispenser. In some preferred embodiments the dispenser facing side of the end plug cooperates with the roll holder portion to rotatably mount the end plug to the holder portion of the dispenser i.e. to permit rotation between the end plug and the roll holder portion. The roll facing side of the end plug may fixedly mount the end plug to the end of the roll of sheet material i.e. to prevent relative rotation between the end plug and roll. However, in other embodiments, the dispenser facing side of the end plug may cooperate with the holder portion to fixedly mount the end plug to the roll holder portion of the dispenser i.e. to prevent relative rotation between the end plug and the roll holder portion. In such embodiments the roll holder portion of the dispenser may be rotatably mounted to a cooperating part e.g. an adjacent part of the dispenser whereby the roll, end plug and roll holder portion may rotate together to permit rotation of the roll relative to at least a portion (e.g. a main body) of the dispenser. The cooperating part may be a dispenser arm of the dispenser. Thus, the roll holder portion may be provided at a distal end of a dispenser arm, and may be rotatably mounted thereto. The roll holder portion may be in the form of a hub rotatably mounted to the distal end of the dispenser arm. The roll holder portion may be rotatably mounted to the dispenser arm (e.g. to a distal end thereof) via a mounting portion e.g. hub. The roll holder portion is then rotatably mounted to the mounting portion. The mounting portion is fixedly mounted to the dispenser arm. In this way the roll holder portion and end plug are rotatably mounted to the distal end of the arm.

The end of the roll of sheet material may be a first end thereof, the moulded end plug a first end plug, and the roll holder portion a first roll holder portion of the dispenser. The roll of sheet material may further comprise an opening in a second end thereof, and a second moulded fibrous end plug in accordance with the invention in any of its aspects or embodiments secured to the second end of the roll of sheet material, wherein the formations of the roll facing side configured to be insertable into an opening in an end of a roll of sheet material are inserted into the opening in the second end of the roll of sheet material. Formations of the roll facing side of the end plug inserted into the second end of the roll of sheet material secure the end plug to the second end of the roll of sheet material. The first and second end plugs are distinct end plugs. The first and second end plugs may be identical. The formations associated with the dispenser facing side of the second end plug cooperate with the formations of a second roll holder position of the dispenser to mount the end plug to the dispenser. The end plugs may rotatably mount the roll of sheet material to the dispenser to enable rotation of the roll relative to at least a portion of the dispenser in any of the manners described above. Each end plug may cooperate with its respective holder portion in the same manner i.e. to rotabably or fixedly mount the end plug thereto.

The dispenser may be of any suitable type. The dispenser may be an electronic dispenser e.g. for hands-free dispensing of sheet material, or may be manually operated. The dispenser may be operable to dispense a predetermined length of sheet material. The dispenser may be a wall-mounted dispenser.

The roll holder portion of the dispenser may be associated with a dispenser arm. For example, the roll holder portion may be provided at a distal end of a dispenser arm. In other embodiments, as discussed above, the roll holder portion may be rotatably mounted to a mounting portion associated with a dispenser arm e.g. at a distal end thereof. In either case, the dispenser may comprise a pair of dispenser arms, each having a roll holder portion associated with the distal end thereof. A space may be defined between the roll holder portions for receiving the roll of sheet material. The dispenser arms may be resiliently mounted to a portion of the dispenser e.g. to opposed sides thereof.

The end plug may be specific to the type of dispenser, such that the formations associated with the dispenser facing side of the end plug are configured to cooperate with formations of only that type of dispenser to mount the end plug to the dispenser. Providing a roll with end plug(s) inserted in the end(s) thereof may then help to ensure that the roll of sheet material is only usable with a type of dispenser with which it is intended to be used e.g. the ensure optimum operation.

The end plug of the present invention is associated with only a single roll.

The present invention extends, in a further aspect, to a roll product comprising a roll of sheet material having an opening in an end thereof, and a moulded fibrous end plug in accordance with the invention in any of its aspects or embodiments secured to the end of the roll with the formations of the roll facing side of the end plug configured to be insertable into an opening in an end of a roll of sheet material being inserted into the opening in the end of the roll. Formations of the roll facing side of the end plug inserted into the end of the roll of sheet material secure the end plug to the end of the roll of sheet material.

It will be appreciated that any of the further aspects of the invention may include any or all of the features of the invention described in relation to any other aspects and embodiments of the invention to the extent they are not mutually inconsistent therewith. In particular, it will be appreciated that the invention in the second and further aspects may comprise any or all of the features described in respect of the method of the first aspect of the invention, and vice versa.

The roll has first and second ends. The roll may comprise openings in both ends thereof. A moulded fibrous end plug in accordance with the invention in any of its aspects or embodiments is secured to at least one, and preferably each end of the roll, with the formations of the roll facing side of each end plug being inserted into the opening at the respective end of the roll. One end plug is secured to each end of the roll. The end plugs may be identical.

The or each opening is defined at an axial end of the roll. The roll may define openings in each axial end thereof i.e. at first and second ends thereof. The or each opening extends axially into the interior of the roll. The opening may be an end of a bore extending through the roll from one end to the other, or may, for example, be an indentation extending only along a portion of the length of the roll. The opening may be any opening to which an end plug can be secured by virtue of the formations associated with the roll facing side thereof.

The or each opening may have a central axis aligned with a central axis of the roll.

The or each opening may be defined by a core of the roll of sheet material. Thus, the roll may be a cored roll. In such cases the opening may be an end of a bore extending through the roll from one end to the other that is lined by a core. However, the end plugs described herein may equally be used with coreless rolls.

The end plug has a length corresponding to only a portion of a length of the roll in a direction connecting the ends of the roll. Where first and second end plugs are associated with first and second ends of the roll, the end plugs are spaced from one another along an axis of the roll.

The end plug may be designed to have a strength such that it may not be removed from a roll after depletion of the roll e.g. from a core thereof without damage. The end plug may thus be intended to be used to mount only one roll to a dispenser and to then be disposed of after that roll is depleted.

The roll of sheet material may be any type of roll of sheet material. The roll may be a roll in which sheet material is dispensed from a periphery of the roll. The roll may define an axial direction. The length of the roll is measured in the axial direction. The axis extends from one end of the roll to the other. The roll is a central axis (i.e. radially central).

The roll may be cylindrical. Where provided, a core may be a cylindrical core.

The sheet material may be any suitable web material. For example, the material may be paper, e.g. where the roll provides paper towels, toilet tissue or facial tissue, nonwoven material, e.g. where the roll provides wipers, or may be any other suitable web material. In some preferred embodiments the sheet material is a paper material for providing paper towels or toilet tissue. The roll of sheet material may or may not be perforated.

A roll of sheet material may be supplied to a consumer with end plug(s) inserted in the end(s) thereof, and preferably with end plugs inserted in openings at each end thereof for use in refilling a dispenser. The system may then provide a refill for a dispenser. The roll with the end plug(s) inserted in the end(s) thereof may be packaged in an outer packaging e.g. an outer wrap. The roll product may therefore provide a roll product refill for a dispenser. The end plugs may be inserted into the end of the roll during production of the roll product by machine.

The method extends to the use of an end plug in accordance with the invention in any of its aspects or embodiments to mount a roll of sheet material to a dispenser. The method may comprise inserting the formations of the roll facing side configured to be insertable into an opening in an end of a roll of sheet material into an opening in an end of the roll to secure the end plug thereto, and mounting the dispenser facing side of the end plug to the roll holder portion of a dispenser such that the formations thereof cooperate with formations of the roll holder portion to mount the end plug thereto, and thereby mount the roll to the dispenser. The formations of the roll facing side for securing the end plug to the roll of sheet material cooperate with the opening in the end of the roll to secure the end plug thereto when the formations of the roll facing side insertable into an opening are inserted into the opening in the end of the roll. The roll and dispenser may include any of the feature described herein.

It will be appreciated that any of the further aspects of the invention may include any or all of the features of the invention described in relation to any other aspects and embodiments of the invention to the extent they are not mutually inconsistent therewith. In particular, it will be appreciated that the invention in the second and further aspects may comprise any or all of the features described in respect of the method of the first aspect of the invention, and vice versa.

The fibres used in making the end plug may be of any suitable type. The fibers are preferably biodegradable fibers. The fibers are preferably natural fibers. The fibres may include virgin fibres, but for improved sustainability, may comprise or consist of recycled fibers. For example, fibers may be obtained from waste paper or any other fiber containing source of waste material. Waste paper or other waste material such as wood or vegetable waste, or any combination thereof, may advantageously provide a source of e.g. cellulosic fibers for use in producing the end plugs described herein.

The fibers may be of any suitable length. By way of example and not limitation, the fibers may comprise or consist of fibers having a length of up to 50 mm or up to 20 mm or up to 10 mm or up to 5 mm. The fibres may have a length of at least 0.5 mm or at least 1 mm.

The end plug preferably comprises cellulosic fibers. The cellulosic fibers may include wood pulp or non wood pulp fibers. Non-wood pulp fibers such as bamboo, bagasse, straw etc. may be used. Such alternative non-wood pulp cellulosic fibers are increasingly used in papermaking. Other types of natural fibers may be used e.g. wool, silk etc. or other non plant based fibers. In exemplary embodiments, whether or not they comprise cellulosic fibers, the fibers of the end plug may comprise papermaking fibers.

The end plug is preferably plastic free. The end plug is preferably free from thermoplastic fibers. The end plug preferably contains only natural fibers.

The moulded fibrous end plug of the invention in any of its aspects and embodiments may be readily recycled e.g. with a waste paper recycling stream.

Preferably the end plug is biodegradable. For example, the end plug may be compostable, e.g. home compostable. The end plug may be such that it may be recycled with paper products. This enables the end plug to be recycled along with a roll core when used. Biodegradable and/or compostable embodiments may provide yet further benefits in terms of sustainability.

The end plug is a moulded end plug. Any suitable moulding process may be used.

The present invention extends to a method of manufacturing the moulded fibrous end plug in accordance with any of the embodiments described herein.

The present invention extends to a method of manufacturing a moulded fibrous end plug in accordance with any of the aspects or embodiments of the invention described herein. The method comprises providing the moulded fibrous end plug using a moulding process. The moulding process may, for example, be an injection moulding process. An injection moulding process refers to a process in which material from which the end plug is to be formed is injected into a mould in producing the end plug. In embodiments the moulded fibrous end plug is an injection moulded end plug.

The mould may be of any suitable form. The mould is configured to produce the formations associated with the roll facing and dispenser facing sides of the end plug. The mould may comprise opposed mould parts, the mould parts respectively comprising internal formations for producing the formations associated with each side of the end plug. The mould may comprise a first part comprising internal formations for producing the formations associated with the roll facing side of the end plug, and a second part comprising internal formations for producing the formations associated with the dispenser facing side of the end plug. The formations associated with the roll facing side comprise the formations insertable into the opening in an end of a roll. The formations associated with the dispenser facing side comprise the formations for cooperating with formations of a holder portion of a dispenser. The internal formations associated with the first and second mould parts are complimentary to the formations to be produced on the respective sides of the end plug.

References herein to the roll facing side of the end plug or the dispenser facing side of the end plug comprising “formations” (e.g. formations configured to be insertable into an opening in an end of a roll of sheet material, formations for securing the end plug to the roll of sheet material, formations configured to cooperate with formations of a roll holder portion of a dispenser in use for mounting the end plug to the dispenser etc.) should be understood to encompass the roll facing side or dispenser facing side comprising a set of one or more, and optionally a plurality of such formations. Thus, the roll facing side of the end plug comprises a set of one or more formations configured to be insertable into an opening in an end of a roll of sheet material and including a set of one or more formations for securing the end plug to the roll of sheet material, and optionally comprises a plurality of formations configured to be insertable into the opening including a plurality of formations for securing the end plug to the roll of sheet material. The dispenser facing side of the end plug comprises a set of one or more, and optionally a plurality of formations which are configured to cooperate with formations of a roll holder portion to mount the end plug thereto. Thus, the dispenser facing side of the end plug comprises a set of one or more formations configured to cooperate with formations of a roll holder portion of a dispenser in use for mounting the end plug to the dispenser, and optionally comprises a plurality of formations configured to function in this manner.

It will be appreciated that any of the further aspects of the invention may include any or all of the features of the invention described in relation to any other aspects and embodiments of the invention to the extent they are not mutually inconsistent therewith. In particular, it will be appreciated that the invention in the second and further aspects may comprise any or all of the features described in respect of the method of the first aspect of the invention, and vice versa. Various features of embodiments of the invention will be described in further detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments will now be described, by way of example only, and with reference to the accompanying drawings in which:

FIG. 1 illustrates one exemplary embodiment of a dispenser with which the end plugs described herein may be used;

FIG. 2 is a front on view illustrating the front face of the roll holder portion which comprises formations which may cooperate with the formations of the dispenser facing side of an end plug in accordance with an embodiment of the invention to mount the end plug to the dispenser;

FIG. 3 is a side on view of the roll holder portion of the embodiment of FIG. 2 ;

FIG. 4 is a perspective view of the roll holder portion of the embodiment of FIG. 2 ;

and FIG. 5 illustrates the way in which the roll facing side of an end plug may be used to mount an end plug to a roll 120.

FIG. 1 illustrates one exemplary embodiment of a dispenser with which the end plugs described herein may be used. This dispenser is merely used as an example to illustrate how a roll holder portion may cooperate with the end plug to mount a roll to a dispenser. It will be appreciated that other dispenser types may be used. The configuration of the roll holder portion of the dispenser, and its relationship to other dispenser parts e.g. the configuration of any dispenser arms, may vary from that shown. Furthermore, while the invention will be exemplified in relation to a roll holder portion which is not rotatable relative to the dispenser arm, in other embodiments, the end plug may, as previously described, fixedly mount the roll to a roll holder portion, which is rotatable relative to another part of the dispenser. For example, the roll holder portion may be in the form of a rotatable hub.

The dispenser illustrated is a wall mounted dispenser, as may be found, for example in a washroom or other hand washing facility. However, end plugs may be used with other types of dispenser. The dispenser may be an electronic hands-free dispenser, although this is not necessarily the case.

Returning now to the exemplary arrangement of FIG. 1 , which is in accordance with WO 2012/073203A2, the dispenser 100 includes a pair of dispenser arms 102, each having a roll holder portion 104 at the distal end thereof. A roll receiving space 106 is defined between the arms 102. The dispenser arms 102 are able to resiliently deflect outwardly relative to one another during insertion or removal of a roll, being biased to return to their original, closer position.

The roll holder portions of a dispenser with which an end plug of the present invention is used may be of the configuration illustrated in FIG. 1 , or indeed any of the configurations described in WO 2012/073203A2 above, or indeed, any other desired configuration.

In use the end plug (already inserted in the end of a roll) is pushed on to the front face of the roll holder portion to mount the end plug, and hence the roll thereto.

The general principles of providing a mounting between and end plug and roll holder portion using cooperating formations on the dispenser facing side of the end plug and the roll holder portion of the dispenser are described in WO 2012/073203A2.

One alternative example of a roll holder portion 50 which may be used with end plugs in accordance with some exemplary embodiments of the invention is shown in FIG. 2 .

FIG. 2 is a front on view illustrating the front face of the roll holder portion which comprises formations which may cooperate with the formations of the dispenser facing side of an end plug in accordance with an embodiment of the invention to mount the end plug to the dispenser. In this example, the formations cooperate with one another to rotatably mount the end plug to the roll holder portion. FIG. 3 is a side on view of the roll holder portion of FIG. 2 . FIG. 4 is a perspective view of the roll holder portion.

The roll holder portion 50 includes a base 52, defining a front face of the roll holder portion. A cylindrical projection 54 extends from the base 52. A circumferentially extending structure 56 partially surrounds the projection 54 so as to define an annular space 58 therebetween. The structure 56 defines a circumferentially extending wall 60 which defines the outer edge of the annular space 58. A ramp structure 62 extends from the top of the wall 60 to the base 52.

In this example, the roll holder portion 50 includes a male formation, the cylindrical projection 54. The formations of the dispenser facing side of the end plug may then comprise a female part for receiving the cylindrical projection. The cylindrical projection 54 and the female part of the dispenser facing side of the end plug are complimentary to one another. The formations of the dispenser facing side of the end plug are configured such that they may cooperate with the formations of the roll holder portion to mount the end plug to the roll holder portion. For example, the formations of the dispenser facing side may be configured such that a female part thereof may cooperate with the formations of the roll holder portion to enable the female part to receive the male part e.g. cylindrical projection. Thus, the female part may be configured such that it fits into the annular space 58 to mount the end plug to the dispenser. The formations of the dispenser facing side of the end plug should be such that they do not interfere with any of the formations of the roll holder portion i.e. the roll facing side thereof to prevent fitting together of the end plug and roll holder portion as required for providing a secure mounting, and, where applicable, to allow relative rotation between the end plug and roll holder portion.

Of course, the roll holder portion may differ from that shown, and the formations of the end plug should be configured as appropriate to enable the formations of the dispenser facing side of the end plug to cooperate with the formations of a particular roll holder portion with which the end plug is intended to be used. For example, rather than a single formation defining a cylindrical projection 54 of the roll holder portion, such a projection may formed by a plurality of formations. The cylindrical projection is then defined by a set of formations of the roll holder portion. This set of formations and a set of one or more formations of the dispenser facing side of the end plug (e.g. defining a cooperating female part thereof) may define ones of a pair of complimentary parts of the dispenser facing side of the end plug and the roll holder portion. The formations of the roll holder portion need not define a cylinder. For example, provided that an outer diameter corresponding to an outer circular boundary drawn around each of the formations defining the projection may snugly fit within the annular formation of the dispenser facing side of the end plug, the arrangement may operate in the same manner as the example of FIGS. 2-4 . Likewise, an annular space may be defined surrounding the projection of the roll holder portion in a manner other than that shown e.g. by a plurality of formations surrounding the projection. The formations need not define a circumferentially extending structure. For example, a series of spoke-like formations extending radially on the face of the roll holder portion may be disposed with their proximal ends spaced from the outer edge of the projection to define an annular space. Similarly there may be more than one ramp portion.

An end plug may be used to ensure that a roll of sheet material is only used with a dispenser with which it is intended to be used e.g. to ensure optimum performance. For example, a dispenser, particularly although not necessarily an electronic dispenser, may be configured to operate most effectively with a particular type of sheet material (e.g. basis weight) and/or configuration of roll. This may ensure that the dispenser operates reliably without jamming, with greater energy efficiency if electronic, without risk of malfunction and/or safety risk etc. It will be seen from the above example, that the formations of the dispenser facing side of an end plug may be configured such that they will only allow the end plug to be mounted to a particular dispenser, having a roll holder portion with appropriate formations.

While the embodiment illustrated permits relative rotation between the end plug and roll holder portion, such that the end plug may rotate with a roll during dispensing, in alternative embodiments, the formations of the roll facing side of the end plug may cooperate to provide a keyed connection with the roll holder portion, such that the roll holder portion and end plug are maintained in a fixed rotational relationship. The roll holder portion may then be rotatably mounted to an adjacent portion of the dispenser to enable rotation of the roll and roll holder portion relative to another part of the dispenser during dispensing. The roll holder portion may be rotatably mounted to an arm of the dispenser, such as via a mounting portion e.g. hub fixed to the distal end of the arm.

FIG. 5 illustrates the way in which the roll facing side of an end plug may be used to mount an end plug to a roll 120. The Figure illustrates one exemplary embodiment of a roll with which the end plug may be used. This Figure, which is in accordance with WO 2012/073203A2, is merely exemplary in general of the way in which an end plug is used. The end plug 101 includes a roll facing side 105 having formations which are insertable into an opening in an end of a roll of sheet material to secure the end plug to the roll, and a dispenser facing side 103 having formations which cooperate with a roll holder portion of a dispenser to mount the end plug thereto. The formations associated with the roll facing and dispenser facing sides 105, 103 of an end plug in accordance with the invention, which is made from a moulded fibrous material, may differ from those shown in FIG. 5 , which illustrates a plastic end plug 101. However, the principles of operation of the end plug will be the same. The roll is a roll of sheet material 108, such as paper towel. However, the sheet material may be of any other type of web material which is suitable for dispensing from a roll. For example, the roll may be a roll of paper material, e.g. for use in providing a hand towel, facial tissue, toilet tissue, or a nonwoven material, e.g. for use in providing a wiper etc. The sheet material may or may not include perforations. The roll dispenses sheet material from the periphery 109 thereof, and is rotatably mounted to a dispenser such that the roll may be rotated to allow the dispensing of material in use.

The roll has ends 121, 123. The roll 120 includes an central bore 126 extending from one end to the other along a central axis 110 thereof. In the illustrated embodiment, the bore 126 is defined by the central bore of a core 122 of the roll. The core 122 may be of any suitable material, such as cardboard, paperboard etc. For example, it may be spirally wound core. However, it will be appreciated that the end plugs described herein are not limited to use in the context of a cored roll, and may be used with any roll having an opening in an end thereof into which the formations of the roll facing side 105 may be inserted. For example, a coreless roll may include openings in the form of indentations extending only a small distance along the axis thereof at each end into which the formations of the roll facing side 105 can be inserted, or may similarly have a central bore, extending from one end to the other. Where the end plug is used with a cored roll, it may be referred to as a “core plug”.

The end plug 101 is inserted into the opening provided by the end of the bore 126 at the end 121 of the roll with the roll facing side 105 leading as schematically shown in FIG. 5 . The formations of the roll facing side which extend from the base 107, are inserted into the end of the bore 126 at the end 121 of the roll. The formations include formations which cooperate with the periphery of the bore 126, provided by the radially inner surface of the core 122 in this case, to provide an interference fit between the end plug 101 and the roll 120.

The end plug 101 may be mounted into the roll by pushing the end plug into the end of the bore 126 after manufacture of the roll, as part of a manufacturing process to provide a refill product comprising the roll with the end plugs fitted, which can be supplied to the user. Thus, in such arrangements, the end plugs are inserted by machine. The roll may be packaged with end plugs inserted in both ends for supply to a user.

While the insertion of the end plug has been illustrated by reference to the end 121 of the roll, it will be appreciated that another end plug of identical construction will be inserted into the opposite end 123 of the roll, in this case cooperating with the opposite end of the central bore 126. While the invention has been illustrated by reference to the case in which a roll includes end plugs at both ends, depending upon the configuration of a dispenser with which it is intended to be used, it is envisaged that an end plug might only be inserted into an opening at one end of a roll to mount the roll to a dispenser.

The use of an end plug in accordance with the invention will now be described.

The end plug is inserted into an opening at one end of a roll of sheet material to be mounted to a dispenser, in the manner as described by reference to FIG. 5 . Typically another such end plug is also inserted into an opening at the other end of the roll of sheet material. This may be performed during manufacture of a refill roll product. The formations of the roll facing side of the end plug provide a secure interference fit to the roll. The roll and its end plug(s) provides a single unit for (re)filling a dispenser. The user may remove any outer packaging from the roll refill product before fitting the roll to a dispenser.

In order to fit the roll to a dispenser, the user first removes any depleted roll along with its end plugs from the dispenser. The user then pushes the dispenser facing side of the end plug at one end of the roll onto the roll holder portion of a dispenser, such as described by reference to FIG. 1 or 2-4 . In the case of dispenser as shown in FIG. 1 , the dispenser arm 102 deflects outwardly to enable the roll to be pushed onto the roll holder portion. The formations associated with the dispenser facing side cooperate with the formations of the roll holder portion 104 to mount the end plug, and hence that end of the roll, to the dispenser arm. Where an end plug is associated with the other end of the roll, as may be the case for use with a dispenser of the type shown in FIG. 1 or 2-4 , the formations of the dispenser facing side of the end plug at that end of the roll similarly cooperate with the formations of the roll holder portion of the other dispensing arm, to mount that end of the roll to the dispenser. The ends of the roll may be mounted sequentially or substantially simultaneously. In this way, the end plug(s) securely mount the ends of the roll to the dispenser, in the illustrated embodiment, to permit rotation between the roll and the roll holder portions of the dispenser.

In use, the end plugs remain securely in place in the ends of the roll during use of the dispenser, e.g. during rotation of the roll relative to the roll holder portion. Once the roll is depleted, the roll along with the end plugs may be removed from between the dispenser arms in a reverse of the initial installation procedure. Where the roll is cored roll, the remainder of the roll product will be the core with the end plugs inserted in its ends. The end plugs of the present invention are made of a fibrous moulded material, and may therefore be recycled along with the core in a paper recycling stream. This avoids problems associated with conventional plastic end plugs which would need to be removed from the core to enable appropriate recycling of the plastic end plugs and paper core in separate streams. Even if the roll is not a cored roll, the end plugs of the present invention may readily be recycled in a standard paper stream.

The end plugs of the present invention are advantageously biodegradable. This offers further sustainability advantages, whether or not the end plugs are recycled in a paper stream. For example, the end plugs may be composted, whether at home or industrially.

The present invention may provide a sustainable fibrous end plug which may function in the same manner as a plastic end plug.

The end plug of the present invention in any of its embodiments is a fibrous end plug.

The fibres used in making the end plug may be of any suitable type, and are preferably biodegradable fibers, such as cellulosic fibers. Advantageously the fibers are recycled fibers.

The end plug is obtained using a moulding process. The process may be an injection moulding process in which the material from which the end plug is to be formed is injected into an appropriately configured mould.

The mould may include two parts, having formations for producing the desired formations of the roll facing and dispenser facings sides of the end plug respectively. When closed, the mould may define a mould cavity corresponding the shape of the end plug to be produced. 

1. A moulded fibrous end plug for use in mounting a roll of sheet material to a dispenser, wherein the end plug has a roll facing side comprising formations configured to be insertable into an opening in an end of a roll of sheet material in use, the formations of the roll facing side including formations for securing the end plug to the roll of sheet material; and an opposite dispenser facing side comprising formations configured to cooperate with formations of a roll holder portion of a dispenser in use for mounting the end plug to the dispenser.
 2. The moulded fibrous end plug of claim 1 wherein the formations of the roll facing side for securing the end plug to the roll of sheet material include formations configured to provide an interference fit securing the end plug to the roll.
 3. The moulded fibrous end plug of claim 1 wherein the fibers are cellulosic fibers.
 4. The moulded fibrous end plug of claim 1, wherein the end plug is biodegradable.
 5. The moulded fibrous end plug of claim 1, wherein the end plug is injection moulded.
 6. A roll product comprising a roll of sheet material having an opening in an end thereof, and the moulded fibrous end plug of claim 1 secured to the end of the roll with the formations of the roll facing side of the end plug being inserted into the opening in the end of the roll to secure the end plug to the roll.
 7. A dispenser system comprising; the moulded fibrous end plug of claim 1 and a dispenser comprising a roll holder portion comprising formations configured to cooperate with the formations of the dispenser facing side of the end plug for mounting the end plug to the dispenser in use.
 8. A dispenser system comprising; a dispenser for a roll of sheet material, the dispenser comprising a roll holder portion; a roll of sheet material having an opening in an end thereof; and the moulded fibrous end plug of claim 1 secured to the end of the roll of sheet material; wherein the formations of the roll facing side of the end plug configured to be insertable into an opening in an end of a roll of sheet material are inserted into the opening in the end of the roll of sheet material; and wherein the formations associated with the dispenser facing side of the end plug cooperate with formations of the roll holder position of the dispenser to mount the end plug to the dispenser.
 9. The dispenser system of claim 8 wherein the dispenser facing side of the end plug cooperates with the roll holder portion to rotatably mount the end plug to the holder portion of the dispenser.
 10. The dispenser system of claim 8 wherein the dispenser facing side of the end plug cooperates with the roll holder portion to fixedly mount the end plug to the roll holder portion such that relative rotation between the roll holder portion of the dispenser and the end plug is prevented, wherein the roll holder portion is rotatable relative to a cooperating portion of the dispenser to permit rotation of the roll relative to at least a portion of the dispenser once mounted for the dispensing of sheet material.
 11. The dispenser system of claim 10 wherein the cooperating portion of the dispenser is an arm of the dispenser, the roll holder portion being mounted to the arm of the dispenser via a mounting portion that is rotatable relative to the arm.
 12. A method of using the end plug of claim 1 comprising using the end plug to mount a roll of sheet material to a roll holder portion of a dispenser.
 13. The dispenser system of claim 8 wherein the formations of the dispenser facing side of the end plug and the formations of the roll holder portion which cooperate with one another include respective sets of one or more formations that are complimentary to one another.
 14. The dispenser system of claim 8 wherein the dispenser is a wall-mounted dispenser.
 15. A method of manufacturing the moulded fibrous end plug of claim 1 comprising providing the moulded fibrous end plug using a moulding process.
 16. The method of claim 15 wherein the moulding process is an injection moulding process. 